stv incorporated philadelphia, pa...philadelphia, pa derek maier, p.e. amtrak wilmington, de...
TRANSCRIPT
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Remaining Life Prediction for Rail Vehicles
Kevin Carmody, P.E.
STV Incorporated
Philadelphia, PA
Derek Maier, P.E.
Amtrak
Wilmington, DE
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• Prolong Fleet Retirement
• Consider Overhaul Alternatives
• Avoid Cost of New Fleet Procurement
Why Evaluate Remaining Life?
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• Documentaion Review
• Inspection
• Structural Analysis
• Instrumentation
• Testing
• Analysis
Steps to an Effective Evaluation
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• Undocumented or Unknown Damage
• Fatigue / Cracks in Structure
• Corrosion
Potential NDE Findings
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Sample Finding - Corrosion
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Sample Finding - Corrosion
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• Drawing Review
• Hand Calculation
• 3-D Finite Element Model
Structural Analysis
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Vertical Load: Principal stress (Front end shown)
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Tensile Principal Stress Around Coupler Pocket
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• Accurate Load Path Determination
• Identify High Stress Areas
• Accurate Strain Gage Placement
• Effective Analysis of Potential Repairs
Finite Element Model
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Bolster FEA Loading For Braking Case
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Side Frame FEA Loading for Lateral Loading
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• Strain Gage & Accelerometer
• Test Over Representative Revenue Route
• Sample Vehicle(s)
• Actual Car Loading & Track Condition
Testing
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• Data Collection
• Rainflow Analysis
• Fatigue Curves
– S-N Curve
– FAD Curves / Crack Growth
Analysis of Results
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S-N Fatigue Curve
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FAD Fatigue Curve
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• Interpretation of Results
• Impact of Damaged Areas
– Potential Repair Life Span
• Determination of Options
– Operate As-Is
– Emergent/Interim Repairs
– Overhaul
– Replace
Remaining Life Prediction